Plug Connector Inserts With Automated Wire Position Labeling
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Solution Overview
Problem
The manual assignment of wires to specific positions in electrical connectors is prone to errors, especially in connectors with complex wiring configurations, leading to inefficient and costly production of customized inserts, particularly in small batches, and requiring extensive documentation and time-consuming revisions.
Innovation Solution
A computer-implemented method generates an insert with individually marked wire positions using a software application that processes connector specifications and optimization algorithms to create a control data set for automated labeling, enabling precise and efficient production of customized connectors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual wire assignment is used in connectors with complex wiring configurations, then flexibility in handling customized connector configurations is maintained, but error rate increases and assembly time increases
Solution Approach 1:
The patent uses digital twins and virtual models to create accurate representations of connector configurations. The system generates digital copies of wire assignments and connector geometries, allowing virtual verification and optimization before physical assembly, thereby eliminating manual errors while maintaining customization flexibility
Solution Approach 2:
The patent replaces manual mechanical wire assignment with automated systems including robotic wire strippers, crimpers, and placement machines controlled by software. This substitution eliminates human error in wire assignment while maintaining the ability to handle customized configurations through programmable control
2Device complexity
If manual wire assignment is used, then no automated equipment is required, but assembly time increases and productivity decreases
Solution Approach 1:
The patent implements a dynamic, modular automated assembly system where components can be added or removed based on production needs. The system includes movable robotic arms, adjustable fixtures, and reconfigurable tooling that can adapt to different connector types and production volumes, providing scalability from low to high-volume manufacturing
Solution Approach 2:
The patent divides the connector assembly process into discrete, automated segments including wire cutting, stripping, crimping, and placement. Each segment is performed by specialized automated equipment, allowing parallel processing and significantly increasing assembly speed while keeping individual equipment requirements manageable
3Adaptability or versatility
If customized inserts are produced in small batches, then application-specific requirements are met, but manufacturing efficiency decreases and cost increases
Solution Approach 1:
The patent uses software-controlled parameters to define different connector configurations without changing physical tooling. By modifying digital models, wire assignment patterns, and control program parameters, the system can quickly switch between different customized configurations, enabling efficient small-batch production of application-specific connectors
Solution Approach 2:
The patent implements a universal automated assembly platform that can handle multiple connector types and configurations through software control. The system uses standardized fixtures and reconfigurable tooling that can be programmed for different applications, allowing the same equipment to efficiently produce various customized inserts in small batches
4Loss of information
If extensive documentation and connection plans are used, then wire assignment information is provided, but documentation complexity increases and reading time increases
Solution Approach 1:
The patent replaces extensive physical documentation with digital twins and interactive software interfaces. The system generates digital connection plans that can be displayed on screens, searched, and filtered, eliminating the need for extensive printed documentation while providing complete wire assignment information in an easily accessible format
Solution Approach 2:
The patent introduces software as an intermediary between the connector design and the assembly process. The control software automatically interprets design specifications and generates assembly instructions, eliminating the need for separate complex documentation while ensuring accurate information transmission
Data Source
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AI summary
The present invention provides a computer-implemented method for generating an insert (10) of an electrical connector having individually marked wire insert positions (11), comprising the steps of providing an output data set containing information about wire insert positions (11) to be occupied in the insert (10) to a computing unit; processing the output data set by the computing unit to generate a control data set containing a position pattern of wire insert positions (11) to be labelled in the insert (10); d) providing the control data set to the control unit of a device for transferring the position pattern to the insert (10) or to a labelling element (20) to be connected to the insert (10); and controlling the device and transferring the position pattern to the insert (10) or to the labelling element (20) to be connected to the insert (10) on the basis of the control data set an insert (10) in an electrical connector, a labelling element (20) and an electrical connector comprising an insert (10).